Coking.com 2019 Coke Cutting Systems for India€¦ · Coker in India. Coking.com , Mumbai 2019 ....

Coking.com 2019

Coke Cutting Systems for India

.

Technology, experiences and lessons learned

Mumbai, 13th-14th November 2019

Dr. Wolfgang Paul, RUHRPUMPEN

Introduction

RUHRPUMPEN Specialist for Pump Technology

Our Mission: Become a worldwide companyLocation: RuhRPumpen Witten, Germany

1950 Founded in Witten / GermanySpecialist for: API Process pumps

API Pipeline pumps for Crudle Oil, Products, Water

1963 Part of THYSSSEN AGTHYSSEN RUHRPUMPEN

1997 Part of Cooperation EG, Monterrey, Mexico

2000 Start with Hydraulic Decoking System

2001 First Order: Petroleras Ameriven/04 ConocoPhillips, PdVSA, Chevron Texaco

Since that time orders for revamps, newUnits and Components


Witten, GermanyArea: 48,000 m²Testing: 8,850 HP

Aerial picture of Witten Plant by Bavaria Luftbild Verlags GmbH

Tulsa, USAArea: 28,000 m² Testing: 2,000 HP

Monterrey, MexicoArea: 14,370 m²Testing: 7,500 HP

Changzhou, ChinaArea: 7,500 m²

Testing: 6,000 HP

Chennai, IndiaArea: 7,500 m²

Testing: 6,000 HP

Orland, CaliforniaArea: 2,500 m²

Ruhrpumpen Business Units

Rio de Janeiro, BrazilArea: 7,500 m²

Testing: 6,000 HP

Suez, EgyptArea: 2,280 m²

Testing: 2,680 HP

Buenos Aires, ArgentinaArea: 7,500 m²

Testing: 1,500 HP

Area definition

Coking.com , Mumbai 2019

CCA -50C/-59F

CA -29C / -20F

WWA +50C/+120F

Coker in India


Company Location Coke Drums

IOCL Bau1 Barauni 2 drumIOCL Guw Guwahati 2 drumIOCL Bon1 Bongaigon 2 drumIOCL Bon2 Bongaigon 2 drumRIL DTA Jamnagar 8 drumNRL 1 Numaligarh 2 drumIOCL Digboi Digboi 2 drumIOCL Pan Panipat 4 drumRIL SEZ Jamnagar 8 drumBORL Bina Bina 2 drumIOCL Guj Gujarat 4 drumHMEL Bhatinda 4 drumMRPL Mangalore 4 drumIOCL Par Paradip 4 drumEssar Vadinar 6 drumBPCL Kochi 4 drumCPCL Chennai 2 drumIOCL Bau2 Barauni 2 drumRIL DTA Jamnagar 2 drumIOCL Hal Haldia 2 drum

Coke per drum

Mass of cokeper drumto cut


Project Schedule, Live cycle

Live cycle years

• Decision by owner and financing 0• Licensor 1• EPC• Purchasing

– Long lead items 4– Bulk material

• Construction 6– Commissioning

• Start up, start of operation 8– Warranty 10– Post warranty 10 + 5

• Modernization and upgrade


Basic requirementsIndia Projects with state own companies

No deviation bidsJUST TECHNCIAL ACCEPTABLE, we don’t pay a premium100% according specification

Result• Required technology with PTR is more than 10 years old• Basic Requirements don’t support deviations and improvements

• New technologies and improvements will be considered late– 1990 – 2000 acceptable– 2000 – 2010 changes in private companies influenced the state own sector– 2010 – 2020 moderate changes in specification– 2020 - not according the fast growing demands of economy in India



Project Specification - Licensor

Jet Pump unit• Design related to coke cutting system

(API 610, 613, 614)• Flow and Head defined very precise,

• often without relation to detailed piping

Mechanical Design Instrumentation and Control

Control System• Licensor spec., basic• PLC redundant,• Basic Logic and Safety requirements•

Cutting System• Design spec. with basic requirement

• Pneumatic / hydraulic / electric

• Basic spec. of CCS-components• Detail design responsibility by CCS vendor• NO definition of power of Cutting System

Instrumentation• Project P&ID

• Detailed design by CCS supplier


Project Specification - EPC

Jet Pump unit + auxiliaries1. Design acc. API 610, 613, 6142. Client specification3. EPC specification (- no deviation )

4. Manufacturer standard / Experience


Control System• Licensor spec. • Client specification• EPC requirement

• High safety -> QMR/TMR• SIL rated (Safety) PLC

Cutting System• No deviation

• All components to 1.- 3.• Special components

• NO detail definition• ie:Auto-Tool, CH-FFA, hoist, HPU, VFD

Instrumentation• No deviation

• All components to 1.- 3.• All to AVL (App-Vendor-List)

• 100% to licensor P&ID


Project execution - Supplier

Jet Pump unit• acc. Licensor / EPC and Decoking

Service requirements


Control System• Licensor and EPC spec. • PLC redundant• Safety requirements by Licensor• Logic by supplier

• System responsibility• Data analysis

Cutting System• Main differences

• Power, Features

• Hoists• Drill Stem Drives, RJ• Crosshead and FFA

• Free Fall Arrestors

• Cutting Tool• Important is pressure at the Tool

Instrumentation• Project P&ID • RP improvements

• Additional instruments

Power of Cutting System

Powerof CuttingSystem- Hoist- Pulleys- Rope- Load in

derrick


Development of Technology

Drive of Cutting Systems



Project Situation

Cutting System DriveElectrical - technical and commercial advantages

- costs for hydraulic or electric systems are equal- total costs are lower

- cabling is much cheaper than piping- less risk

Live cycle costs- maintenance costs are much lower with electrical

equipment- no oil consumption, no oil treatment

Benefits have not been balanced to the supplier

Ruhrpumpen to Owner / PMC / EPC


RP improvements

Cutting SystemCrosshead Wheel typeFree Fall Arrestor Rail type system, certified as elevator componentControl System Monitors at Pumps and Cutting deck with interactive

P&IDsTool Automatic Drilling / Cutting Tool

Most of the features are now standard featurebecause they were just implemented

not specified

Supply of Ruhrpumpen to Projects in India


RP improvements

RIL II - Hydraulic driven cutting systemIOCL Gujarat - Spec. change to hydraulic driven cutting systemHMEL - Cutting System with 5t/20t pullforce of hoist/Crosshead

- first electrical driven cutting system in India- designed for remote and automatic operation

MRPL - Hydr. Cutting System with 5t/20t pullforce of hoist/CrossheadNOCL - Electrical Cutting System with 5t/20t pullforce of hoist/CHIOCL Paradip - Hyd Cutting System with 5t/20t pullforce of hoist/CrossheadIOCL Barauni - Electrical Cutting System with 5t/20t pullforce of hoist/CHCPCL - Hydraulic Cutting System with 5t/20t pullforce of hoist/CHIOCL Haldia - Electrical Cutting System with 5t/20t pullforce of hoist/CH.

Since than, all Cutting Systems are specified electrical driven

Projects in India with RP influence


Project Situation

Licensor pid : “detail design according Coke Cutting System supplier”PMC : “no deviation to licensor pid“EPC : “Deviation with approval of PMC only“

Example

Piping: - Suction Line

- 2 Jet Pump - installation- Jet Pump: Suction flange and area with MAWP

- Discharge Line- Size of discharge line


Project Situation, Pump arrangement

Project: all projects are designed with TWO PUMP arrangementincrease of reliability of coker

Licensor : Suction and Discharge design to full MAWPEPC : Deviation only with approval of PMC and licensor

India

Problem: - Full pressure suction line- Reduced inside, effective diameter- Suction pressure instrumentation away from the suction flangeSituation- Pressure drop in pump suction is much higher then measured

CokerCoker Client 1

private


Jet PumpClient 1Jet Pump area

- 2 Pumps installed- Jet Pump unit

sheltered


Jet PumpClient 1Jet Pump area

2x Jet Pumps installed- Sheltered

Suction Line- Low Pressure - High Pressure

Tank- Suction Inlet Basket


CokerIndia: Client 1Start up 2010Problem: Cavitation Investigation of

TankSuction LinePump


Result: Change of - Suction Line- Suction Basket- Pumps run ok

CokerCoker Client 5

state ownedDrum 4 Dia maxFF maxPump 2 Flow maxPressure max


CokerIndia: Installation 2015


CokerIndia: Suction Line Investigation Start up 2017Check 2018



Ruhrpumpen Issues

Project bid: according spec, but lowest costsand high competitive situation

Selection of suppliers : start 2000 castings for pump internals from Germany2005 - 2010 castings, high quality, from SK2010 - 2015 castings from low cost foundry, country 12015 - 2019 castings from low cost foundry, country 22019 - castings from high quality foundry, country SK

RP had to develop the low cost supplierthis was painful long time of correction due to project schedule

Meanwhile the quality of casting is good, acceptable and acc. RP spec

Ruhrpumpen


Cutting System

Specification: no definition of pullforce nor lifting systemno relation to size of coker

Ruhrpumpen has always provided the strong Cutting / Lifting Systemaccording Ruhrpumpen standard, above requirements, 5 t / 20 t Lift System, 0 to high speedaccepted by all parties, because on RP costs

Lessons learnedwe did not went away from our high standard for cost savingswe want to keep high performance and high reliability

Project

Lifting SystemIndia: Client 4Cutting Deck

- Hoist- electrical driven- slack rope device- 3 brake system- safety cage- full baseframe

Capacitypull force hoist 5 tpull force at tool 20 tpull speed 0 – 1 m/s

Operation- local- ( remote / auto)


Crosshead with DSDClient 4Derrick

Crossheadwheel typeFree Fall Arrestor

Meeting larger tolerances in derricks compared to shoe type crossheads

Drill Stem Drive- electrical driven- No oiled main bearing

All weather protected


Automatic Cutting ToolBasic design

– Slim tool, OD 13”– Low lift force, low torque

• Switching devices• Mode Indicator

– At the top of the tool

• Valves– No seals– Pressure operated

• Nozzles, cutting– 0° / 0°

• Nozzles, drilling– 1 strong centre nozzle– 3 periphery nozzles



Control System

Project bid: according spec, with acceptable costswith additional features

RP has increased level of Control System and Operationacc. RP standard, above requirementsmonitors with all available data and informationinteractive P&ID’s high acceptance by all operatorsready for remote and auto cutting, even when not specified

Meanwhile, most of the features are standard for Coke Cutting Systems

Ruhrpumpen


Control systemClient 4Operator cubicle

- Operation in – heated– prewired– Fire

resistend material

– Safety glass– Round and

top view

CS - typicalOperator Panel

Control building



Lessons learned

Target: Mechanical System on high safety level of the entire systemCreate a Standard NOT JUST TECHNICAL ACCEPTABLE

Discuss with Licensors to implement improvementsConvince Final Clients about benefits of additional featuresEPC’s go for low costs, EPCs don’t implement advantages

provide costs savings to EPC

System Design

RUHRPUMPEN: Complete System responsibility out of one hand Design: Strong mechanical system with double mechanical safetyControl System is just to operate the mechanical system.

It cannot balance mechanical weakness.Costs Don’t go to the lowest cost level.


Experience

Design: Modification of RP standard to specific needs of Indian Clients

Discussion, relation and contacts on high level with Client with high expertise and experiences in coker businessEPC’s with very good knowledge to meet local requirementsIt is necessary to understand Indian mentality

Coke Cutting System

RUHRPUMPEN: we formed a strong relation to our clientsSystem responsibility not only in good times

Start: We started to work out of Germany, but nowActual: RUHRPUMPEN INDIA with manufacturing facility in Chennai

growing support team for coker

THANKS FOR YOUR

ATTENTION

Questions ?

RUHRPUMPEN


Coking.com 2019 Coke Cutting Systems for India€¦ · Coker in India. Coking.com , Mumbai 2019 ....

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Transcript of Coking.com 2019 Coke Cutting Systems for India€¦ · Coker in India. Coking.com , Mumbai 2019 ....